Appendix A: Example Calculation of Exhaust Flow Rate, Percent Moisture and Percent Oxygen

C 70.6 Excess Air (%) 15

H2 22.7 Temperature (std.) 350

N2 5.7 Heating Value (Btu/lb) 22027

S --

Ash --

O2 1

Calculate Theoretical Oxygen Requirement in Combustion Air:

Element % by weight Molecular weight

Mole/100 lb of 

fuel=%/MW

Resulting 

Product

Required 

moles of 

Ox/ 100 

lb fuel

C 70.6 12 5.9 CO2 5.9

H2 22.7 2 11.4 H2O 5.7

N2 5.7 28 0.2

O2 1 32 0.03 -0.03

Total 100 11.6

22027 Btu/lb fuel x 100/100 lb fuel x MMBtu/1000000 Btu = 2.2MMBtu/ 100 lb fuel

15 = 100 x (O2 - 11.6)/11.6

O2 = 13.3 molesO2/100 lb fuel

Material Analysis Average Values for Natural Gas from Steam

Fuel Values and Combustion Unit 

Assumptions

Calculate Heat Content of Natural Gas per 100 lb of fuel

Solve for Required Moles of O2/100 lb fuel at 15% excess air
Appendix A: Example Calculation of Exhaust Flow Rate, Percent Moisture and Percent Oxygen

Ratio of N2 to O2 in the Atmosphere - 3.77 [moles N2 to moles O2]

N2 = 13.3 moles O2/100 lb fuel x 3.77 moles N2/1.0 mole O2

N2 = 50.1 moles/100 lb fuel

Calculate Exhaust Totals

Element Basis Exhaust (moles/100 lb fuel)

CO2 5.9 C 5.9

H20 11.4 H2 11.4

O2 13.3 - 11.6 1.7

N2 0.2+50.1 50.3

Total 69.3

Calculate Exhaust Volume acf/lb fuel

Pressure x Volume = Moles x Constant x Temperature

Exhaust Volume = Moles x constant x Temperature / Pressure

Constant = 10.73 psia-ft3/lb-mole-deg R

Temperature Conversion deg R = deg F + 460

Calculate Exhaust Volume acf/MMBtu

Exhaust Volume = Volume in acf/lb fuel x Heat Content per 100 lb fuel

Exhuast Volume = 409 acf / lb fuel x 100 lb fuel / 2.2 MM Btu = 18590 acf/MMBtu at 15% excess air

Calculate Exhaust Flow Rate from Exhaust Volume using Example Capacity of 5 MMBtu/hr

Exhaust Flow rate = Exhaust Volume in acf/MMBtu x Capacity in MMBtu/hr x 1 hr/60 minutes

Exhaust Flow Rate = 18590 acf/MMBtu x 5 MMBtu/hr x 1/60 = 1549 acfm

Calculate Percent Moisture in Exhaust

Exhaust Moisture (%) = (11.4 moles H2O/100 lb fuel) / 69.3 total moles/100 lb fuel x 100% = 16.5 %

Calculate Percent Oxygen in Exhaust

Exhaust Moisture (%) = (1.7 moles O2/100 lb fuel) / 69.3 total moles/100 lb fuel x 100% = 2.5 %

Sources:

Exhuast Volume = 69.3 lb-moles / 100 lb fuel x 10.73 psia-ft3/lb-mole-deg R x (1/14.7psia) x (350 deg F + 460) = 409 acf / lb fuel

Calculate Moles of N2/100 lb fuel in Combustion Air

Alvis, Jeanette, C. Burlew and R. Oommen, ERG. Development of Model Units for the Industrial/Commercial/Institutional Boilers and Process Heaters National Emision 

Standards for Hazardous Air Pollutants. October 2002.
Appendix B: Fabric Filter Costs

Parameters/Costs Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr)

2. Annual operating hours, hr/yr (H) used Boiler Survey data as input

3. Exhaust gas flow rate, dscfm (Q) calculated per boiler, see Section 2.0 of the memo.

4. PM concentration, gr/dscf (PM) calculated baseline emission factor for PM (lb/mmBtu)*C*(7000/60)/Q

5. Water vapor in gas (% by weight) (%M) estimated per boiler, see Section 2.0 of the memo.

 a. lb/min = Q / (385 ft3

/lb-mol) x (29 lb/lb-mol) x %M

 b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3

/lb-mol)

 a. Dry gas from boiler, Btu/lb air = [7.010 x (300°F - 77°F) - 7.554 x (1800°F - 77°F)] / (29 lb/lb-mol)

 b. Water vapor from boiler, Btu/lb water 

vapor

= [8.154 x (300°F - 77°F) - 9.215 x (1800°F - 77°F)] / (18 lb/lb-mol)

 c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x (60 min/hr) x H] 

+ [(Btu/lb water vapor) x Q x (0.00753 lb water vapor/ft3) x (60 

min/hr) x H]

 d. Cooling water

 i. Heat of vaporization at 77°F, Btu/lb 1050

 ii. Sensible heat for vapor, Btu/lb 85

 iii. Total, Btu/lb water 1135

7. Cooling water evaporated, lb/yr

 a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change 

(cooling water, Btu/lb)]

 b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3/lb-mol) / 

(H * 60 min/hr)

8. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from incinerator, scfm) + (water vapor 

added in quench, i.e., cooling water evaporated, scfm)] x [(300°F + 

460°F)/528°R]

9. Operating labor rate, $/hr (LR) 51.26

10. Electricity cost, $/kWh (EC) 0.069981

11. Water cost, $/gal (WC) 0.000559

12. Compressed air cost, $/1,000 ft3 (CAC) 0.31

13. Dust disposal cost, $/ton (DDC) 42.14

14. Capital recovery factors = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = equipment life

 a. Bag CRF, 2-yr life, 7% interest

 b. Cage CRF, 4-yr life, 7% interest

 c. Equipment CRF, 20-yr life, 7% interest

 d. Duct CRF, 20-yr life, 7% interest

15. Cost index

 a. 2008 525.4

 b. 1989 357.5

16. Retrofit Factor 1.4

17. Gas transport velocity, ft/min (ut) assigned constant, 3000

18. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2

19. Number of Duct Lines, (ND)

 if Q < 154042 acfm =1

 if Q > 154042 acfm = Q/154042 acfm

20. Length of ductwork (L) assigned constant, 500

21. # of elbows per length of duct (Ne/Ld) assigned constant, 0.02

22. Fan coefficient (af) assigned constant, 22.1

23. Fan Diameter, inches (Df) assigned constant, 36.5

24. Fan exponent (b) assigned constant, 1.55

B. Total Capital Investment

1. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x 

EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x 

(Df^b))))

2. TCI $ = (47.0 x Q + 306,720) x (Retrofit Factor) x (525.4/357.5)+TCIduct

3. $/dscfm = $ / Q

C. Direct Annual Operating Costs, $/yr

1. Electricity = (0.746 kW/hp) x hp (0.0072 x Q + 3.20) x H x EC

2. Electricity - Ducts

 a. Friction loss factor for elbow (k) assigned constant, 0.19

 b. Efficiency of fan (ef) assigned constant, 0.70

 c. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x 

(ut/4016)^2)

 f. Electricity for Fan use, kW (Efan) =((0.000117 x Q x H x Pd)/ef)

 g. Cost of Electricity, $/yr =EC x Efan

3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 min/hr) x H x WC

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR

5. Supervisory labor = 0.15 x (operating labor)

6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)

7. Maintenance materials = 0.02 x TCI

8. Compressed air = AQ x (2 ft3

 air/1,000 ft3 filtered) x (60 min/hr) x H x CAC

9. Dust disposal = (PM gr/dscf x Q x 60 min/hr x 1 lb/7,000 gr) x (1 ton/2,000 lb) x H x 

DDC

10. Bag replacement

 a. Bag cost = AQ x ($2.5/ft2

) x (525.4/317.4) x (1.08 taxes and freight ratio)/(3.5 

ft/min G/C ratio)

 b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2

 bag area)/(3.5 ft/min G/C ratio) x LR

 c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag replacement labor cost)]

11. Cage replacement

 a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2

 bag area)

 b. Cage replacement labor cost = bag replacement labor cost

 c. Cage replacement cost = Cage CRF x [single-cage cost (4.941+ 0.163 x 18 ft2

 bag area) x 

(number of bags) x (525.4/317.4) + (cage replacement labor cost)]

6. Enthalpy change in quench (1800°F to 300°F)
Appendix B: Fabric Filter Costs

Parameters/Costs Equation

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials)

2. Property taxes, insurance, and 

administration

= 0.04 x TCI

3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement 

cost)

4. Duct TAC

 a.TACductwork =TCIduct x (0.04 + CRFduct)

 b. Duct_cap recov =TACductwork x 0.7

 c. Duct_admin =TACductwork x 0.1498

 d. Duct_prop tax =TACductwork x 0.0749

 e. Duct_insurance =TACductwork x 0.0749

 f. Total TACduct =Duct_cap recov + Duct_admin + Duct_prop tax + Duct_insurance

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs + Total TACduct

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

4. Water cost: Air Compliance Advisor, version 7.5.

5. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004.

6. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and 

Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific 

Occupational Employment and Wage Estimates
Appendix C: ESP Costs

Parameters/Costs Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr)

2. Annual operating hours, hr/yr (H) used Boiler Survey data as input

3. Exhaust gas flow rate, acfm (Q) calculated per boiler, see Section 2.0 of the memo.

4. PM concentration, gr/dscf (PM) calculated baseline emission factor for PM (lb/mmBtu)*C*(7000/60)/Q

5. Efficiency, % (E) =100*(1-(PM emission limit/PM))

6. Temperature (T) assigned based on fuel type, see Section 2.2.2 of the memo

7. Inlet Moisutrue, % (IM) assigned constant, see Appendix C-2

8. Specific Collection Area ratio (SCA) assigned based on efficiency, see Appendix C-2

9. PM Migration velocity (Mv) assigned constant, see Appendix C-2

10. Total Collection Place area, ft2 (TCP) =(Q/1000) x ((-508*LN(1-(E/100)))/Mv) x SCA

11. Equipment Cost of ESP, $ (EC)

 if TCP<50,000 =614.55(TCP)^0.6276

 if TCP>50,000 =57.87(TCP)^0.8431

12. Factor to convert from FRP to other material 

(m)

assigned constant, see Appendix C-2

13. Cost index

 a. 2008 525.4

 b. 1998 389.5

14. Capital recovery factors = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = equipment life

 Equipment CRF, 20-yr life, 7% interest

 Duct CRF, 20-yr life, 7% interest

15. Operating labor rate, $/hr (LR) SEE cost input summary

16. Electricity cost, $/kWh (EC) SEE cost input summary

17. Dust disposal cost, $/ton (DDC) SEE cost input summary

18. Retrofit Factor 1.4

19. Gas transport velocity, ft/min (ut) assigned constant, see Appendix C-2

20. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2

21. Number of Duct Lines, (ND)

 if Q < 154042 acfm =1

 if Q > 154042 acfm = Q/154042 acfm

22. Length of ductwork (L) assigned constant, see Appendix C-2

23. # of elbows per length of duct (Ne/Ld) assigned constant, see Appendix C-2

24. Fan coefficient (af) assigned constant, see Appendix C-2

25. Fan Diameter, inches (Df) assigned constant, see Appendix C-2

26. Fan exponent (b) assigned constant, see Appendix C-2

B. Total Capital Investment (TCI)

1. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x 

EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x 

(Df^b))))*(575.4/389.5)*Retrofit Factor

2. $ =3.8326 x m x EC x Retrofit Factor + TCIduct

3. $/acfm = $ / Q

C. Direct Annual Operating Costs, $/yr

1. Electricity

 a. Friction loss factor for elbow (k) assigned constant, see Appendix C-2

 b. Efficiency of fan (ef) assigned constant, see Appendix C-2

 c. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x 

(ut/4016)^2)

 d. Pressure drop through ESP, in.H2O (Pesp) assigned constant, see Appendix C-2

 e. Pressure drop of gas, in.H2O (Pg) =Pesp+Pd

 f. Electricity for Fan use, kW (Efan) =((0.000117 x Q x H x Pg)/ef) + 0.00194 x TCP x H

 g. Cost of Electricity, $/yr =EC x Efan

2. Dust disposal =0.00000429 x H x DDC x PM x Q x E

3. Labor

 a. If TCP < 10,000 then Of =0

 b. If TCP > or = 10,000 then Of=1

 c. Cost of Labor, $/yr (LC) = 0.1854 x H x LR x Of

4. Maintenance Cost, $/yr (MC)

 a. If TCP<50,0000 =4125 + 0.004464 x TCI

 b. If TCP> or = 50,000 =0.0825 x TCP + 0.00446 x TCI

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (LC + MC)

2. Property taxes = 0.01 x TCI

3. Capital recovery = Equipment CRF x (TCI)

4. Administrative cost =0.02 x TCI

5. Insurance =0.01 x TCI

6. Duct TAC

 a.TACductwork =TCIduct x (0.04 + CRFduct)

 b. Duct_cap recov =TACductwork x 0.7

 c. Duct_admin =TACductwork x 0.1498

 d. Duct_prop tax =TACductwork x 0.0749

 e. Duct_insurance =TACductwork x 0.0749
Appendix C: ESP Costs

Parameters/Costs Equation

 f. Total TACduct =Duct_cap recov + Duct_admin + Duct_prop tax + Duct_insurance

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs + Total TACduct

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 6. EPA/452/B-02-001, January 2002.

2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process Heaters 

National Emission Standards for Hazardous Air Pollutants, October 2002.
Appendix C: ESP Costs

Var COMMON DEFAULTS - ESP

I I = interest rate 0.07

Ne_Ld Ne/LD = # of elbows per length of duct 0.02

L L = length of ductwork 500

ut ut = gas transport velocity, ft/min 3000

Var DEFAULTS- TOTAL ANNUAL COST -- ESP

n n = life of equipment, yrs 20

Op_ESP Op_ESP = operating hours/year 8400

CFdd CFdd = cost factor for dust disposal, $/ton 42.14111

CFlab CFlab = cost factor for labor, $/hr 51.26

Ps = DEFAULTS - ELECTRICITY - ESP

CFelec CFelec = cost factor for electricy, $/kw-hr 0.06998

Pesp Pesp = pressure drop through esp, in H2O 0.38

k k = friction loss factor for elbow 0.19

Ef Ef = efficiency of fan 0.7

DEFAULTS - DUCTWORK - ESP

af af = fan coefficient 22.1

b b = fan exponent 1.55

Df Df = fan diameter, inches 36.5

n_duct n_duct = life of equipment, yrs 20

DEFAULTS -TCI - ESP

Fone Fone = special add-on factor 1

Ftwo Ftwo = no special add-on factor 0

m m = factor to convert from FRP to other mat. 1

Mv Mv = PM migration velocity, cm/s 16

Sources:

ESP DEFAULTS

1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 6. 

EPA/452/B-02-001, January 2002.

2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional 

Boilers and Process Heaters National Emission Standards for Hazardous Air Pollutants, October 2002.
Appendix D: Packed Bed Scrubber

Parameters/Costs Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr)

2. Annual operating hours, hr/yr (H) used Boiler Survey data as input

3. Exhaust gas flow rate, acfm (AQ) calculated per boiler, see Section 2.0 of the memo.

4. PM filterable baseline emission, lb/mmBtu (PMb) used Boiler Survey data as input

5. HCl Baseline, lb/mmbtu (HClb) used Boiler Survey data as input

6. Temperature (T) assigned based on fuel type, see Section 2.2.2 of the memo

7. Inlet Moisutrue, % (IM) calculated per fuel type, see Appendix D-2

8. HCl Floor, lb/mmBtu (HClf) assigned based on fuel

9. Efficiency (E) = 100 x (1 - (HClf/HClb))

10. Inlet HCl Loading, lb/hr (In HCl) =HClb x C

11. Inlet PM loading, lb/hr (In PM) = PMb x C

12. Inlet HCl loading, mole fraction (In HClm) =InHCl x (T = 460) / (2958.12 x AQ)

13. Inlet PM loading, gr/acfm (InPMg) =InPM / AQ x 116.7

14. Packing Cost Factor, $/ft3 (Cp) constant, see Appendix D-2

15. Scrubber Diameter Component (SDC)

 a. ratio of solvent density to water density (mm) defined in Appendix D-2

 b. packing factor (Fp) defined in Appendix D-2

 c. viscosity of liquid, lb/ft-hr (ui) defined in Appendix D-2

 d. flooding factor (f) defined in Appendix D-2

 e. minimum wetting rate, ft2/hr (MWR) defined in Appendix D-2

 f. packing constant, ft2/ft3 (ap) defined in Appendix D-2

 g. SDC '=(-0.915 - SQRT(-1.144359 -(1.188 x (LOG((mm x Fp x ((ui / 2.42) ^ 0.2) x MWR^2 x 

ap^2) / (12960000 x f^2 x 32.2),10)))))/-0.594

16. Scrubber Diameter, ft (Ds)

 a. density of liquid, lb/ft3 (Dl) defined in Appendix D-2

 b. density of gas, lb/ft3 (Dg) defined in Appendix D-2

 c. Ds =(SQRT((240 x Dg x AQ x 10^SDC)/(MWR x Dl x ap x PI x SQRT((Dg/Dl)))))

17. Height of packing, ft (Hpack)

 a. packing constant (BBB) defined in Appendix D-2

 b. packing constant (X) defined in Appendix D-2

 c. HpackA = X x (240 x Dg x AQ) / (PI x Ds^2)

 d. packing constant (g) defined in Appendix D-2

 e. HpackB = (MWR x D x ap)^g

 f. viscosity of gas, lb/ft-hr (ug) defined in Appendix D-2

 h. diffusivity of gas, ft2/hr (Dfg) defined in Appendix D-2

 i. HpackC = SQRT(ug/(Dg*Dfg)

 j. packing constant (BB) defined in Appendix D-2

 k. HpackD =((MWR x Dl x ap)/ui)^BB

 l. liquid diffusivity, ft2/hr (Dfl) defined in Appendix D-2

 m. HpackE = SQRT(ui/(Dl x Dfl))

 n. pollutant mole fraction exiting scrubber(Out 

HClm)

=In HClm x (100-E)/(100 - (In HClm x E))

 o. adsorption factor (AF) defined in Appendix D-2

 p. packing constant (t) defined in Appendix D-2

 q. Hpack =Ln(In HClm/Out HClm) x (HpackA/HpackB^BBB) x HpackC + 1/AF x (t x HpackE^BB) 

x HpackE

18. Cost factor for pump, $/gpm (Cfpump) defined in Appendix D-2

19. Factor to convert FRP to another material defined in Appendix D-2

20. Cost Index

 a. 2008 525.4

 b. 1998 389.5

21. Capital recovery factor (CRF) = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = equipment life

 Equipment CRF, 20-yr life, 7% interest

 Duct CRF, 20-yr life, 7% interest

22. Operating labor rate, $/hr (CFlab) $51.26

23. Electricity cost, $/kWh (CFelec) $0.069981

24. Water cost, $/gal (CFw) $0.00059889

25. Wastewater disposal cost, $/gal (CFww) $0.005439

26. Pump Cost Factor, $/gpm (CFp) $23.64

27. Cost Factor for Caustic, $/ton (CFcaus) $600
Appendix D: Packed Bed Scrubber

Parameters/Costs Equation

28. Moles of caustic/moles pollutant (SR1) defined in Appendix D-2

29. Caustic mole weight, lb/lbmole (MWcaustic) defined in Appendix D-2

30. Gas molecular weight, lb/lb-mole (MWg) defined in Appendix D-2

31. Moles salt/moles HCl (SR2) defined in Appendix D-2

32. Salt molecular weight, lb/lbmole (MWsalt) defined in Appendix D-2

33. Fraction of waste stream treated (BF) defined in Appendix D-2

34. Maintenance labor rate, $/hr (Cfmain) $51.26

35. Retrofit Factor 1.4

19. Gas transport velocity, ft/min (ut) defined in Appendix D-2

20. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2

21. Number of Duct Lines, (ND)

 if Q < 154042 acfm =1

 if Q > 154042 acfm = Q/154042 acfm

22. Length of ductwork (L) defined in Appendix D-2

23. # of elbows per length of duct (Ne/Ld) defined in Appendix D-2

24. Fan coefficient (af) defined in Appendix D-2

25. Fan Diameter, inches (Df) defined in Appendix D-2

26. Fan exponent (b) defined in Appendix D-2

B. Total Capital Investment (TCI)

1. TCItower, $ =(417.956 x m x PI x Ds x Hpack) + (453.7808 x m x PI x Ds^2) + 

(838.8974 x m x PI x Ds)

2. TCIp, $ =0.649 x Cp x Hpack x PI x Ds^2

3. TCIpump, $ =0.0312 x MWR x a x PI x Ds^2 x Cfpump x m

4. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x 

EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x 

(Df^b))))

5. Total TCI, $ = (TCItower + TCIpump + TCIp + TCIduct) x (525.4/389.5) x Retrofit 

Factor

6. $/acfm = $ / Q

C. Direct Annual Operating Costs, $/yr

1. Electricity

 a. Pressure of pump, ft of H2O (Pp) defined in Appendix D-2

 b. Efficiency of pump (Ep) defined in Appendix D-2

 c. Electricity for Pump use, kw (Epump) =(0.00000585 x H x PI x Ds^2 x MWR x ap x Pp) / Ep

 d. Friction loss factor for elbow (k) defined in Appendix D-2

 e. Efficiency of fan (ef) defined in Appendix D-2

 f. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x 

(ut/4016)^2)

 g. packing constant (c) defined in Appendix D-2

 h. packing constant (j) defined in Appendix D-2

 i. Pressure drop through scrubber, in.H2O (Ps) =(Hpack x AQ^2 x c x Dg x [10^(j x MWR x Dl x ap / 3600)]) / (225 x PI^2 x Ds^4)

 j. Pressure drop of gas, in.H2O (Pg) =Ps+Pd

 k. Electricity for Fan use, kW (Efan) =((0.000117 x AQ x H x Pg)/ef)

 l. Cost of Electricity, $/yr (Ce) =EC x (Epump + Efan)

2. Caustic Cost ($/yr), Ccaustic =0.03 x AQ x Dg x (In HClm - Out HClm) x SR1 x MWcaustic x H x 

CFcaus / MWg

3. Cost of ww disposal, $/yr (Cww) =7.194 x AQ x Dg x (In HClm - Out HClm) x SR2 x Mwsalt x (1/BF) x H 

x CFww / MWg

4. Cost of water, $/yr (Cw) =Cww x (CFw / CFww)

5. Cost of Labor, $/yr (Clab) = 0.07188 x H x Cflab

6. Cost of Maintenance, $/yr (Cmain) =0.125 x H x Cfmain

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (CFlab + CFmain)

2. Property taxes = 0.01 x TCI

3. Capital recovery = Equipment CRF x (TCI)

4. Administrative cost =0.02 x TCI

5. Insurance =0.01 x TCI

6. Capital recovery = CRF x TCI

7. Duct TAC

 a.TACductwork =TCIduct x (0.04 + CRFduct)
Appendix D: Packed Bed Scrubber

Parameters/Costs Equation

 b. Duct_cap recov =TACductwork x 0.7

 c. Duct_admin =TACductwork x 0.1498

 d. Duct_prop tax =TACductwork x 0.0749

 e. Duct_insurance =TACductwork x 0.0749

 f. Total TACduct =Duct_cap recov + Duct_admin + Duct_prop tax + Duct_insurance

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs + Total TACduct

2. ($/yr) / acfm = ($/yr) / AQ

Sources:

1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 8. EPA/452/B-02-001, January 2002.

2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process Heaters National 

Emission Standards for Hazardous Air Pollutants, October 2002.
Appendix D: Packed Bed Scrubber

Var COMMON DEFAULTS - PACKED SCRUBBER

I I = interest rate 0.07

Dg Dg = density of gas, lb/ft3 0.0709

Ne_Ld Ne/LD = # of elbows per length of duct 0.02

L L = length of ductwork 500

MWR MWR = minimum wetting rate, ft2/hr 1.3

ut ut = gas transport velocity, ft/min 3000

Dl Dl = density of liquid, lb/ft3 62.4

ap a = packing constant, ft2/ft3 28

Var DEFAULTS- TOTAL ANNUAL COST -- PACKED SCRUBBER

n n = life of equipment, yrs 15

SR1 SR1 = moles caustic/moles pollutant 0.5

MWc MWc = caustic molec wt, lb/lb-mole 62

Op_Scr Op_Scr = operating hours/year 8400

CFc Cfc = cost factor for caustic, $/ton 440

MWg MWg = gas molecular weight, lb/lb-mole 29

SR2 SR2 = moles salt/moles HCl 1

MWs MWs = salt molecular weight, lb/lb-mole 58.5

BF BF = fraction of waste stream treated 0.1

CFww CFww = cost factor for ww disposal, $/gal 0.0054

CFwt CFwt = cost factor for water, $/gal 0.00060

SR3 SR3 = adjustment for 76% Na2O solution 0.76

CFlab CFlab = cost factor for labor, $/hr 51.26

CFmain CFmain = cost factor for maintenance, $/hr 51.26

DEFAULTS - ELECTRICITY - PACKED SCRUBBER

CFelec CFelec = cost factor for electricy, $/kw-hr 0.06998

Pp Pp = pressure of pump, ft of H20 60

Ep Ep = efficiency of pump 0.7

Op_pump Op_pump = operating hours/year 8000

cpc cpc = packing constant 0.24

j j = packing constant 0.17

k k = friction loss factor for elbow 0.35

ef ef = efficiency of fan 0.7

DEFAULTS - DUCTWORK - PACKED SCRUBBER

af af = fan coefficient 22.1

b b = fan exponent 1.55

Df Df = fan diameter, inches 36.5

n_duct n_duct = life of equipment, yrs 20

PACKED SCRUBBER DEFAULTS
Appendix D: Packed Bed Scrubber

DEFAULTS -TCI - PACKED SCRUBBER

m m = factor to convert from FRP to other material 1

mm mm = ratio of solvent density to water density 1

Fp Fp = packing factor 65

ui ui = viscosity of liquid, lb/ft-hr 2.16

f f = flooding factor 0.7

ug ug = viscosity of gas, lb/ft-hr 0.044

Dfg Dfg = diffusivity of pollutant in gas, ft2/hr 0.725

Dfl Dfl = diffusivity of pollutant in liquid, ft2/hr 0.000102

AFT AFT = absorption factor 17

x x = packing constant 3.82

t t = packing constant 0.0125

g g = packing constant 0.45

BBB BBB = packing constant 0.41

bb b = packing constant 0.22

eff eff = efficiency of scrubber 99

Cp Cp = packing cost factor, $/ft3 20

CFpump CFpump = cost factor for pump, $/gpm 23.64

Site Site 0

Bldg Bldg 0

Sources:

2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process 

Heaters National Emission Standards for Hazardous Air Pollutants, October 2002.

1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 8. EPA/452/B-02-001, 

January 2002.
Appendix E: Increased Caustic

Parameters/Costs Equation Fuel Category F-Factor

Bagasse 9420

A. Parameters Coal 9780

1. Annual operating hours, hr/yr (H) used Boiler Survey data as input Dry Biomass 9240

2. Exhaust gas flow rate, acfm (AQ) calculated per boiler, see Section 2.0 of the memo. Gas 1 8710

3. Exhaust gas flow rate, dscfm (Q) calculated per boiler, see Section 2.0 of the memo. Gas 1 - Metal Furnace 8710

4. Baseline HCl, units (lb/mmBtu) (HClb) calculated per boiler Heavy Liquid 9190

5. Floor HCl level, (lb/mmBtu) (HClf) assigned by fuel category Light Liquid 9190

6. F-Factor determined by fuel category, see index Non-Continental Liquid 9190

7. Uncontrolled HCl, ppmvd (HClu) =HClb x F-Factor x (1/36.4609) x 385.34 x 1000000 Process Gas 8710

8. Controlled HCl, ppmvd (HClc) =HClf x F-Factor x (1/36.4609) x 385.34 x 1000000 Wet Biomass 9600

9. Operating Labor Rate, $/hr (LR) $51.26

10. Wastewater Blowdown, gpm (B) =Hclu/1000000 x Q x 1/385 x 1/1 x 58.2/1 x 1/0.1 x 

1/8.33

11. Caustic Cost, $/ton (CC) $357

12. Sewage disposal, $/1000 gal (SDC) $5.40

13. Water Cost, $/1000 gal (WC) $0.60

14. Lime Cost, $/ton (LC) $95

15. Sodium Bicarbonate, $/ton (SBC) $440

16. Dust Disposal, $/ton (DDC) $34.29

17. Activated Carbon, $/lb (ACC) $1.38

18. Natural Gas, $/1000 ft3 (NGC) $9.58

19. Electricity Cost, $/kWh (EC) $0.07

20. Capital recovery factors = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a 

= equipment life

 a. Bag CRF, 2-yr life, 7% interest

 b. Cage CRF, 4-yr life, 7% interest

15. Cost index

 a. 2008 525.4

 b. 1984 317.4

B. Total Bag/Cage Cost

1. $ = AQ x 2.5 x (525.4/317.4) x (1.08/3.5)

2. Bag Replacement Labor Cost = AQ x 0.15/18/3.5 x LR

3. Cage Replacement Labor Cost = Bag Replacement Labor Cost

4. Total Cage Cost = Cage CRF x ((4.941 + 0.163 x 18) x (AQ/3.5/18) x 

(5.75.4/317.4) + Cage Labor Cost

C. Total Increased NaHCO3 Cost

1. Makeup NaHCO3 Cost, $ = 2.73x10-7 x Hclu x Q x 1/2000 x 60 x H x SBC

2. Dust Disposal Cost, $ =HCLu x Q x 60 x 2.1x10-7 x 1/2000 x H x DDC

3. Total Cost, $/yr/dscfm =(Makeup NaHCO3 + Dust Disposal Cost) /Q

D. Increased Carbon Cost

1. Activated Carbon Cost, $ =1.27x10-3 x Q x H x ACC

2.Dust Disposal Cost, $ =1.27x10-3 x Q x 1/2000 x H x DDC

3. Total Cost, $/yr/dscfm = (Activated Carbon Cost + Dust Disposal Cost)/Q

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry 

Injection Fabric Filter Cost Memorandum (IV-B-32).
Appendix F: Activated Carbon Injection Model Costs

Equation

A. Parameters For fly ash waste rate calcs:

1. Boiler design capacity, Btu/hr (C) used Boiler Survey data as input

Fuel Category Coal Type HHV 

(Btu/lb) Ash content

2. Exhaust gas flow rate, dscfm (Q) calculated per boiler, see Section 2.0 of the memo. Bagasse N/A 4000 0.017

3. Annual operating hours, hr/yr (H) used Boiler Survey data as input Coal Bituminous 11000 0.12

4. Carbon cost, $/ton (Ca) = 1500 Coal Sub-Bituminous 8400 0.06

5. Waste disposal cost, $/ton (WD) = 42.14 Dry Biomass N/A 8623 0.031

6. Higher heating value, Btu/lb (HHV) fuel specific, see table to right Gas 1 - Metal Furnace N/A -- 0

7. Ash content of fuel, % (A) fuel specific, see table to right Gas 1 N/A -- 0

8. Boiler ash removal, % (AR) = .2 Heavy Liquid N/A 18990 0.005

9. Carbon feed rate, lb/hr (CF) If boiler equipped with fabric filter, then

CF = Q x (60 min/hr) / (1,000,000 acf/MMacf) x (2 lb/MMacf)

If boiler is not equipped with fabric filter, then

CF = Q x (60 min/hr) / (1,000,000 acf/MMacf) x (5 lb/MMacf) Light Liquid N/A 19750 0

10. Carbon waste rate, lb/hr (CW) = CF Non-Continental Liquid N/A 18990 0.005

11. Fly ash waste rate, ton/hr (FAW) = C / (HHV) / (2000 lb/ton) x A x (1 - AR) Process Gas N/A -- 0

12. Total waste rate, ton/hr (TW) = FAW + (CF / (2000 lb/ton)) Wet Biomass N/A 8623 0.031

13. Capital recovery factor, 20-yr equipment life, 7% 

interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life

Notes:

B. Total Capital Investment - For liquids the maximum HHV and ash values are used

1. Base cost, $ (BC) = 1,350,000 x (CF0.15) - For wet and dry biomass the average of all four biomass types is used

2. Engineering and Construction Management costs, $ 

(ECM)

= 0.05 x BC

3. Labor adjustment for 6 x 10 hour shift premium, per 

diem, etc., $ (LA)

= 0.05 x BC

4. Contractor profit and fees, $ (CP) = 0.05 x BC

Parameters/Costs

Source:

Babcock and Wilcox. Steam its generation and use 40th edition. Pgs 8-10, 8-15, 8-18. 

4. Contractor profit and fees, $ (CP) = 0.05 x BC 1992.

5. Capital, Engineering and Construction Cost Subtotal 

(CEC)

= BC + ECM + LA + CP

6. Owners costs, $ (OC) = 0.05 x CEC

7. Total capital, $ (TCI) = CEC + OC

C. Annual Cost - Fixed O&M

1. Maintenance material and labor, $/yr (MML) = 0.005 x TCI

2. Administrative labor, $/yr (AL) = 0.03 x 0.4 x MML

3. Total fixed O&M, $/yr (FOM) = MML + AL + (CRF x TCI)

D. Annual Cost - Variable O&M

1. Carbon sorbent, $/yr (CS) = CF x Ca x H / (2000 lb/ton)

2. Waste disposal $/yr (WD) = TW x WD x H

3. Total variable O&M, $/yr (VOM) = CS + WD

E. Total Annual Cost

1. $/yr = FOM + VOM

Sources:

3. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.

2. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase based on 

1. Sargent & Lundy, IPM Model – Revisions to Cost and Performance for APC Technologies: Mercury Control Cost Development 

Methodology (Project 12301-009). March 2011.

1992.
Appendix F: Activated Carbon Injection Model Costs

Equation

A. Parameters

1. Capital recovery factor, 20-yr equipment life, 7% 

interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = 

equipment life

B. Total Capital Investment

1. Slurry additive base cost, $ (SLA) = 500,000

2. Engineering and Construction Management costs, $ 

(ECM)

= 0.05 x SLA

3. Labor adjustment for 6 x 10 hour shift premium, per 

diem, etc., $ (LA)

= 0.05 x SLA

4. Contractor profit and fees, $ (CP) = 0.05 x SLA

5. Capital, Engineering and Construction Cost Subtotal 

(CEC)

= SLA + ECM + LA + CP

6. Owners costs, $ (OC) = 0.05 x CEC

7. Total capital, $ (TCI) = CEC + OC

C. Annual Cost - Fixed O&M

1. Maintenance material and labor, $/yr (MML) = 0.005 x TCI

2. Administrative labor, $/yr (AL) = 0.03 x 0.4 x MML

3. Total fixed O&M, $/yr (FOM) = MML + AL + (CRF x TCI)

D. Annual Cost - Variable O&M

1. Slurry additive system O&M, $/yr (VOM) = 115 x H

Parameters/Costs

If boiler has SCR AND WET FGD is installed for HCl reduction, AND the boiler needs a Hg reduction of less 

than 80% AND the coal is Bituminous -then ACI would not be costed, BUT Slurry Additives are.

E. Total Annual Cost

1. $/yr = FOM + VOM

Sources:

1. Sargent & Lundy, IPM Model – Revisions to Cost and Performance for APC Technologies: Mercury Control Cost 

Development Methodology (Project 12301-009). March 2011.
Appendix F: Activated Carbon Injection Model Costs

Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input

2. Capital recovery factor, 20-yr equipment life, 7% 

interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life

B. Total Capital Investment

1. Slurry additive base cost, $ (SLA) = 500,000

2. Halogen additive system, $ (HA) = 1,000,000

3. Engineering and Construction Management costs, $ 

(ECM)

= 0.05 x (SLA + HA)

4. Labor adjustment for 6 x 10 hour shift premium, per 

diem, etc., $ (LA)

= 0.05 x (SLA + HA)

5. Contractor profit and fees, $ (CP) = 0.05 x (SLA + HA)

6. Capital, Engineering and Construction Cost Subtotal 

(CEC)

= SLA + HA + ECM + LA + CP

7. Owners costs, $ (OC) = 0.05 x CEC

8. Additive royalty fee, $ (ARF) = 2500 x C x (1 kW / 0.00344 mmBtu/hr) / (1000 kW / 1 MW)

9. Total capital, $ (TCI) = CEC + OC + ARF

C. Annual Cost - Fixed O&M

1. Maintenance material and labor, $/yr (MML) = 0.005 x TCI

2. Administrative labor, $/yr (AL) = 0.03 x 0.4 x MML

3. Total fixed O&M, $/yr (FOM) = MML + AL + (CRF x TCI)

D. Annual Cost - Variable O&M

1. Slurry additive system O&M, $/yr (SAVOM) = 115 x H

2. Halogen additive system O&M, $/yr (HAVOM) = 290 x H

3. Total variable O&M, $/yr (VOM) = SAVOM + HAVOM

If boiler has SCR AND WET FGD is installed for HCl reduction, AND the boiler needs a Hg reduction of less than 80% AND the 

coal is Sub-bituminous or Lignite -then ACI would not be costed, BUT Halogen Addition and Slurry Additives are.

Parameters/Costs

E. Total Annual Cost

1. $/yr = FOM + VOM

Sources:

1. Sargent & Lundy, IPM Model – Revisions to Cost and Performance for APC Technologies: Mercury Control Cost Development 

Methodology (Project 12301-009). March 2011.
Appendix G: Low NOx Burners

Parameters/Costs Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 

mmBtu/hr)

2. Annual operating hours, hr/yr (H) used Boiler Survey data as input

3. Unit Size, kW (kW) =C x (1000/3.413)

4. Unit Size, MW (MW) =C x (1/3.413)

5. Capital recovery factor = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, 

a = equipment life

 a. Equipment CRF, 15-yr life, 7% interest

15. Cost index

 a. 2008 525.4

 b. 2004 444.2

B. Total Capital Investment

TCI ($) =20 x kW x (300/MW)^0.359

C. Direct Annual Operating Costs, $/yr

Variable O&M Costs = 0.000293 x H x C x (0.05/1000) x (575.4/444.2)

D. Indirect Annual Costs, $/yr

1. Fixed O&M Costs = 0.015 x TCI

2. Capital recovery = Equipment CRF x TCI

1. $/yr

= Direct Annual Costs + Indirect Annual Costs

Source:

1. ERG, 2005. Analysis of Combustion Controls for Reducing NOx Emissions from Coal-Fired EGUs in the WRAP 

Region September 6, 2005.
Appendix H: Oxidation Catalyst

Parameters/Costs Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 

mmBtu/hr)

2. Annual operating hours, hr/yr (H) 8400

3. Exhaust gas flow rate, scfm (Q) calculated per boiler, see Section 2.0 of the memo.

4. Percent additional fuel/air added (Aux) = Default of 0.05

5. Exhaust gas flow rate, scfm (AF) =Q x (1+Aux)

6. Equipment Cost, $ (EC) = 1105 x Q^0.5471

7. Additional Purchase Equipment Cost 

(Instruments,taxes,freight), $ (AddEC)

= 0.35 x EC

8. Direct Installation Costs, $ (DIC) =0.282 x (EC+AddEC)

9. Indirect Installation Costs, $ (IIC) =0.22 x (EC + AddEC)

9. Operating labor rate, $/hr (LR) 51.26

10. Electricity cost, $/kWh (EC) 0.06998

11. Catalyst cost, $/ft^3 (Cc) 959

12. Pressure change, in of H2O (Pc) 6

13. Efficiency of fan and motor (Ef) 0.6

14. Capital recovery factors = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = 

equipment life

 a. Catalyst CRF, 2-yr life, 7% interest

 b. Equipment CRF, 20-yr life, 7% interest

15. Cost index

 a. 2008 525.4

 b. 1990 390.6

16. Space Velocity in 1/h (Sv) 12000

17. Retrofit Factor 1.4

Total Capital Investment

B. 1. $ =(EC + AddEC + DIC + IIC) x (577.4/390.6) x Retrofit Cost

2. $/scfm

= $ / Q

C. Direct Annual Operating Costs, $/yr 1. Electricity

 a. Power of Fan (Pf) =(0.000117 x AF x Pc)/0.6

 b. Cost of Electricity =Pf x H x EC

2. Operating labor = H/8 x 0.5 x LR

3. Supervisory labor = 0.15 x (operating labor)

4. Maintenance labor = Operating labor

5. Maintenance materials = Maintenance labor

6. Catalyst Replacement

 a. Catalyst Replacement Volume, ft3 (CRV) =AF x 60/Sv

 b. Catalyst Replacement Cost =CRV x Cc x Catalyst CRF
Appendix H: Oxidation Catalyst

Parameters/Costs Equation

1. Overhead = 0.6 x (electricity + operating labor + supervisory labor + 

maintenance labor + maintenance materials + catalyst 

replacement)

D. Indirect Annual Operating Costs, $/yr 2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = Equipment CRF x (TCI - 1.08 x catalyst replacement cost)

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 2. EPA/452/B-02-001, January 2002.
Appendix I: Dry Injection Fabric Filter Costs

Parameters/Costs Equation

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input

2. Annual operating hours, hr/yr (H) used Boiler Survey data as input

3. Exhaust gas flow rate, dscfm (Q) calculated per boiler

4. HCl concentration, ppmvd (HCl) used Boiler Survey data as input

5. PM concentration, gr/dscf (PM) calculated baseline emission factor using Boiler Survey data as input: 

(lb/mmBtu)*C*(7000/60)/Q

6. Water vapor in gas (% by weight) (%M)

 a. lb/min = Q / (385 ft3

/lb-mol) x (29 lb/lb-mol) x %M

 b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3

/lb-mol)

 a. Dry gas from boiler, Btu/lb air = [7.010 x (300°F - 77°F) - 7.554 x (1800°F - 77°F)] / (29 lb/lb-mol)

 b. Water vapor from boiler, Btu/lb water vapor = [8.154 x (300°F - 77°F) - 9.215 x (1800°F - 77°F)] / (18 lb/lb-mol)

 c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3

/lb-mol) x (29 lb/lb-mol) x (60 min/hr) x H] + [(Btu/lb water vapor) x Q 

x (0.00753 lb water vapor/ft3) x (60 min/hr) x H]

 d. Cooling water

 i. Heat of vaporization at 77°F, Btu/lb 1,050

 ii. Sensible heat for vapor, Btu/lb 85

 iii. Total, Btu/lb water 1,135

8. Cooling water evaporated, lb/yr

 a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change (cooling water, Btu/lb)]

 b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3

/lb-mol) / (H * 60 min/hr)

9. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from incinerator, scfm) + (water vapor added in quench, i.e., cooling 

water evaporated, scfm)] x [(300°F + 460°F)/528°R]

10. Operating labor rate, $/hr (LR) $51

11. Electricity cost, $/kWh (EC) $0.069981

12. Lime cost, $/ton (LC) $95

13. Water cost, $/1,000 gal (WC) $0.20

14. Compressed air cost, $/1,000 ft3 (CAC) $0.31

15. Dust disposal cost, $/ton (DDC) $42.14

16. Capital recovery factors (CRF) = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = equipment life

 a. Bag CRF, 2-yr life, 7% interest 0.55309

 b. Cage CRF, 4-yr life, 7% interest 0.29523

 c. Equipment CRF, 20-yr life, 7% interest 0.09439

17. Cost index

 a. 2008 575.4

 b. 1989 357.5

18. Retrofit Factor 1.4

19. Gas transport velocity, ft/min (ut) assigned constant, 3000

20. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2

21. Number of Duct Lines, (ND)

 if Q < 154042 acfm =1

 if Q > 154042 acfm = Q/154042 acfm

22. Length of ductwork (L) assigned constant, 500

23. # of elbows per length of duct (Ne/Ld) assigned constant, 0.02

24. Fan coefficient (af) assigned constant, 22.1

25. Fan Diameter, inches (Df) assigned constant, 36.5

26. Fan exponent (b) assigned constant, 1.55

B. Total Capital Investment

1. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x EXP(0.8016 x (Dd/ND))) + 

(23 x EXP(0.6804 x (Dd/ND))) + (af x (Df^b))))*(575.4/389.5)

2. TCI, $ = (63.8 x Q + 407,498) x (1.4 retrofit cost factor) x (575.4/357.5)+TCIduct

3. $/dscfm = TCI / Q

C. Direct Annual Operating Costs, $/yr

1. Electricity = (0.746 kW/hp) x hp (0.0079 x Q + 3.51) x H x EC

2. Makeup lime = (2.4E-7 lb/dscf x HCl x Q) x (1 ton/2,000 lb) x (60 min/hr) x H x LC

3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 min/hr) x H x WC

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR

5. Supervisory labor = 0.15 x (operating labor)

6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)

7. Maintenance materials = 0.02 x TCI

7. Enthalpy change in quench (1800°F to 300°F)
Appendix I: Dry Injection Fabric Filter Costs

8. Compressed air = AQ x (2 ft3

 air/1,000 ft3 filtered) x (60 min/hr) x H x CAC

9. Dust disposal = [(PM gr/dscf x Q x 60 min/hr x 1 lb/7,000 gr) + (HCl x Q x 60 min/hr x 2.86E-7 lb/dscf)] x (1 

ton/2,000 lb) x H x DDC

10. Bag replacement

 a. Bag cost = AQ x ($2.5/ft2

) x (575.4/317.4) x (1.08 taxes and freight ratio)/(3.5 ft/min G/C ratio)

 b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2

 bag area)/(3.5 ft/min G/C ratio) x LR

 c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag replacement labor cost)]

11. Cage replacement

 a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2

 bag area)

 b. Cage replacement labor cost = bag replacement labor cost

 c. Cage replacement cost = Cage CRF x [single-cage cost (4.941+ 0.163 x 18 ft2

 bag area) x (number of bags) x 

(575.4/317.4) + (cage replacement labor cost)]

12. Electricity of Fans

 a. Friction loss factor for elbow (k) assigned constant, 0.19

 b. Efficiency of fan (ef) assigned constant, 0.70

 c. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x (ut/4016)^2)

 f. Electricity for Fan use, kW (Efan) =((0.000117 x Q x H x Pd)/ef)

 g. Cost of Electricity, $/yr =EC x Efan

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials)

2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement cost)

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

3. Electricity cost: Energy Information Administration. Average Retail Price of Electricity: 2006.

4. Lime cost: U.S. Geological Survey. Mineral Commodity Summaries 2008. Hydrated Lime Average Value, 2007.

5. Water cost: Air Compliance Advisor, version 7.5.

6. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004.

7. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2007 National Industry-Specific Occupational

 Employment and Wage Estimates

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (IIA-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32).
Appendix J-1: Summary of Testing Costs

Liquid Fuel?

Cost per 

Testing Trip Pollutants Tested For

no 28000 CO, PM, HCl, Hg

yes 11000 CO, PM

Notes:

Testing:

Testing Costs were estimated by ERG Air Laboratory Staff in March 2009 and September 2011 and assume that the 

testing contractor will make a single trip to the facility to conduct all necessary tests.

A basic range of testing costs was applied to various pollutants. Tests for PM (filterable), CO, and HCl could be 

completed with manual testing methods, and these manual methods were estimated to range from approximately

$5,000 - $7,000. For the tests that involve more lab analysis (e.g., Hg), the testing costs were estimated to range 

from approximately $10,000 - $15,000. 

Although these cost ranges can be applied as is for cases where a single pollutant is being measured, estimating 

costs for facilities that need test data for more than one pollutant is more difficult and uncertain. For example, if a 

facility needs PM data and CO data, the test costs would not be twice the $5,000 - $7,000 range because some of 

the costs are associated with getting to the site and setting up the equipment. Such costs are one-time costs and 

would not be duplicated no matter how many pollutants are to be tested). Therefore, if a facility had more than one 

of the simpler tests to run (e.g., PM and CO or PM and HCl), then the site-specific cost would start in the $5,000 -

$7,000 with a few $1,000 added for subsequent pollutants. If a facility needed PM data and mercury data, then the 

site-specific cost would be the sum of the test in the $5,000 - $7,000 range and the $10,000 - $15,000 range. 

For liquid fuels, it was assumed that units would comply using a fuel analysis (or by receiving a certified fuel analysis 

from the fuel supplier for HCl and Hg), so the costs for these two tests for Hg and HCl were subtracted from the total 

testing costs.

Repeat Testing:

Provisions in the rule require facilities to identify the worst case fuel or fuel mixture for both chlorine and mercury. 

Many commenters noted that this would require multiple performance tests because the worst case fuel for chlorine 

is not necessarily the worst case fuel for mercury. EPA estimated repeat testing costs for HCl and Hg only at 

$18,000.
Analyzers BEFORE AFTER

 CO 0 1

 SO2 0 0

 NOX 0 0

 HCl 0 0

 Mercury (and CO2/O2) 0 0

 CO2 0 0

 O2 0 0

 THC 0 0

Summary of Costs

First Costs Labor Test ODCs Total

 Planning 4,835 0 352 5,187

 Select Equipment 20,313 0 3,067 23,380

 Support Facilities 0 0 19,065 19,065

 Purchase CEMS Hardware 0 0 61,070 61,070

 Install and Check CEMS 6,534 0 11,979 18,513

 Performance Specification Tests 3,907 11,230 503 15,640

 QA/QC Plan 4,679 14,546 692 19,917

40,269 25,777 96,727 162,773 TCI

Annual Costs

 Day-to-Day Activities 7,503 0 1,000 8,503

 Annual RATA 1,337 10,642 0 11,980

 PM Monitor RCA 0 0 0 0

 PM Monitor RRA 0 0 0 0

 Cylinder Gas Audits (ACA/SVA for PM) 2,034 0 1,069 3,103

 Recordkeeping and Reporting 1,822 0 160 1,982

 Annual QA & O&M Review and Update 3,399 0 1,161 4,560

 Capital Recovery (i=7%, monitor life = 10 years) 5,734 3,671 13,774 23,179

 Total w/o capital recovery 16,095 10,642 3,390 30,128

 Total with capital recovery 21,830 14,313 17,164 53,307 TAC

Source:

U.S. EPA CEMS Cost Model. 03/07/2007. http://www.epa.gov/ttn/emc/cem.html

Appendix J-2: Summary of CO CEMS
Appendix J-3: Other Monitoring Costs for Boilers and Process Heaters

Parameters/Costs Equation

A. Parameters

1. Recording lime/carbon flow, min/4-

hr period

5 5

2. Annual operating hours, hr/yr (H)

3. Cost index

 a. 2008 575.4 575.4 575.4 575.4 All costs are 

in $2008

575.4 575.4 575.4

 b. 2006 499.6 All costs 

are in 

$2006

499.6 All costs are 

in $2006

499.6 All costs for FF 

are in $2006

 c. 2002 395.6 All costs 

are in 

$2002

 d. 1998

389.5

All costs 

are in 

$1997

 e. 1997 386.5 All other costs are 

$1997 386.5

All other costs are 

$1997

 f. 1993 359.2 Equipment costs, 

are $1993 359.2

Equipment costs, 

are $1993

 g. 1992

4. Operating labor wage rate, $/hr 

(LR)

$34.60 $34.60 $34.60 $34.60 $51.26

5. Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

0.09439 0.09439 0.09439 0.09439 0.09439

B. Total Capital Investment, $ (TCI)

1. Planning $700 $800 $900 $1,500

2. Select type of equipment $400 $4,500 $12,200 $4,900

3. Provide support facilities $1,500 $500 $500 $2,000

4. Purchased equipment cost (PEC) $19,300 $14,100 $73,500 $27,100

5. Install and check equipment $1,000 $4,800 $19,500 $5,800

6. Perf. spec. tests (certif.) $700 $0 $35,500 $700

7. Prepare QA/QC plan $700 $800 $15,400 $1,500

8. Total capital cost = Planning + selecting equipment + 

support facilities + PEC + installation + 

perf. spec. tests + QA/QC plan

$24,300 $25,500 $158,000 $115,000 $43,137 $43,500 $8,523

DIFF O2

As reported in survey

Opacity

As reported in survey

WS Bag leak detector PM CEMS ACI
Appendix J-3: Other Monitoring Costs for Boilers and Process Heaters

WS Bag leak detector PM CEMS ACI Opacity DIFF O2 C. Annual Costs, $/yr

1. Operating labor = (5 min to record lime/carbon flow/4-hr 

period) x (1 hr/60 min) x H x LR

2. Maintenance materials = 0.02 x TCI $500 $1,477

3. Operation & maintenance = Day-to-day activities + annual RATA 

+ CGA + annual QA + O&M review 

and update

$6,000 $27,300

$5,909

4. Recordkeeping and reporting = $1,000 x (525.4/386.5) $1,500 $200 $6,300 $1,477

5. Overhead = 0.6 x (labor + maintenance materials) $300

6. Property taxes, insurance, and 

administration

= 0.04 x TCI $1,000

$1,725

7. Capital recovery = CRF x TCI $2,300 $3,500 $22,500 $4,071

8. Total annual cost = Operating labor + maintenance 

materials + recordkeeping and 

reporting + overhead + property taxes, 

insurance, and administration + capital 

recovery

$5,600 $9,700 $56,100 $14,661 $1,436

Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

2. Costs to be replaced include: (a) bag leak detector replacing opacity test; (b) CO CEMS replacing CO test and secondary chamber temperature monitor;

(c) HCl CEMS replacing HCl test, HCl sorbent monitor (dry scrubbers) and scrubber liquor pH monitor (wet scrubbers); (d) PM CEMS replacing PM and

opacity tests and and pressure drop monitor (wet scrubbers); (e) multi-metal/Hg CEMS replacing flue gas temperature monitor (wet scrubbers); (f) dioxin

sorbent trap biweekly monitoring replacing fabric filter inlet temperature monitor; and (g) Hg sorbent trap biweekly monitoring replacing flue gas temperature

monitor (wet scrubbers).

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66).

2. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. July 28, 2006. Some Preliminary Thoughts on the HWI Monitoring.

4. In Situ Oxygen Monitor Costs. EPA Air Pollution Control Cost Manual, Sixth Edition, January 2002, http://www.epa.gov/ttn/catc/dir1/c_allchs.pdf , Equipment cost from Table 4.11 (pg 180).

Based on hrs/yr

Based on hrs/yr

Based on hrs/yr

3. Memorandum from Thomas Holloway, Midwest Research Institute, to Rick Copland, U.S. Environmental Protection Agency, Revised Testing and Monitoring Options and Costs for Medical 

Waste Incinerators (MWI’s) - Methodology and Assumptions. March 17, 1997.

Based on hrs/yr

Based on hrs/yr

Based on hrs/yr